MATL06018 2019 Plastics Materials Selection

Explain the nature of thermoplastic and thermoset polymer materials

Analyse polymer technical property data sheets supplied by material manufacturers

Compile a basic plastic material requirement specification for a given service application

Undertake a basic plastic materials selection based upon the compiled requirement specification

Identify commodity, engineering and high performance thermoplastic/thermosets and principal commercial uses and applications

Identify why, where and when engineering, thermoset and high performance polymers are selected instead of commodity thermoplastics for commercial applications

Apply knowledge and skills to encourage sustainable design and use applications of polymers

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The Nature of Plastics Materials, inc: influence upon design and application.

Commodity Plastics, nature, properties and use applications, materials inc:

- Polyolefines (PP, PE, HDPE, EVA & related materials) .

- Syrinic polymers, inc, PS, HIPS, SAN, ASA, ABS and block co-polymer elastomers.

- PVC based polymers, UPVC, PPVC, formulations, additives, properties and use applications.

- Acrylic (PMMA), properties and use applications.

Engineering Plastics, Definition, nature, properties and use applications, materials inc:

- Polyamides (Nylon 6, 6.6, 11, 12), introduction to fibre reinforcement.

- Polyesters (PC, PET, PETG, PBT).

- POM &PPO introduction to impact modification.

- Polysulphones (PPS & PSU).

- Polyurethanes (TPUR & PU RIM) introduction to elastomeric materials, RIM tooling, RIM applications, processing techniques and product design use requirements.

- Thermoset polymers, Definition, Nature of materials, properties, applications and use formats, polymers inc:

- Un-saturated ester thermoset resins, material nature / properties, format type explanation / format use (GMC, DMC, SMC).

- Epoxide resins (EMC / EP).

- Formaldehyde based resins, inc, UF, MF and PF, material nature / properties, use applications, processing and product design requirements.

- Introduction to Rubber , Vulcanisation, explanation of variant materials inc, NR Latex, SBR, Flouro rubber, etc. Appreciation of rubber compound design and construction.

- Overview of compression moulding and injection moulding thermoset processing techniques, inc, positive lock, semi-positive lock, transfer and flash tooling techniques. Explanation of injection moulding thermoset technology and use applications.

High Performance polymers, Definition, Nature, Properties and Applications, materials inc:

- Polyamides (PAA, PAI), introduction to polymer flow, thermal requirements, conditioning.

- LCP materials.

- PEEK materials.

- High performance injection mould tool construction, inc: steels, loading, bolster plate deflection, feeding, heating and control.

- High performance injection moulding machine, inc: screw design, thermal control, force requirement, etc.

- PTFE based materials and technology, material types / properties, powder sinter technology, compression mould design / moulding techniques and component design. Ram extrusion and moulding technologies explained.

- Plastic Material Additives, inc, thermal stabilizers, UV stabilizers, lubricants, plasticizers, colourants (eg, liquid, universal and polymer specific variants), nature, properties and use applications.

- Reinforcements, inc, glass fibre (long and short variants), fibre matrix theory, Kevlar, carbon fibres, nature / effect, properties of composites, use applications, etc.

- Fillers, inc, Talc, Calcium Carbonate and Graphite, explanation of nature, property modification and application uses. 

- Construction of a polymer product material requirement specification, inc, explanation of thermal use ranges, chemical use environment, appraisal of key mechanical property requirements (eg, tensile, compression, rigidity, impact strength, etc).

Construction and Use of a Plastic Material Selection Matrix.